valve body insert apparatus and related methods are described. An example valve includes a valve body made of a first material and having a fluid flow passageway and a first shaft bore. The fluid flow passageway defines a first axis and the first shaft bore defines a second axis that is substantially non-parallel relative to the first axis of the fluid flow passageway. A first insert is positioned in the first shaft bore. The first insert is made of a second material different than the first material such that the second material has a higher corrosion resistance characteristic than the first material.
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18. An apparatus comprising:
a valve body made of a first material having a low corrosion or erosion resistant characteristic, the valve body defining a fluid flow passageway and a first shaft bore;
a first sleeve positionable in the first shaft bore to line a first inner surface of the first shaft bore to protect the first inner surface of the first shaft bore from corrosion or erosion, the first sleeve made of a second material different than the first material, the second material having a higher corrosion or erosion resistance characteristic than the first material, the first sleeve having a cylindrical body that includes a first end and a second end opposite the first end, wherein the first end is positioned adjacent a third end of the first shaft bore and the second end is positioned adjacent a fourth end of the first shaft bore; and
a cladding material positioned adjacent the third end of the first shaft bore and adjacent the fourth end of the first shaft bore such that cladding material engages the first end of the first insert and the second end of the first insert, wherein cladding material is not applied to portions of the first inner surface of the first shaft bore covered by the first insert.
11. A rotary valve assembly comprising:
a valve body defining a fluid flow passageway between an inlet and an outlet, the valve body having a drive shaft bore formed on a drive side portion of the valve body;
a first insert positioned in the drive shaft bore and coupled to the valve body to line an inner surface of the drive shaft bore leading to the fluid flow passageway, wherein the first insert is configured to protect the inner surface of the drive shaft bore from corrosion or erosion, the first insert including:
a first counterbore to receive a first bushing, the first counterbore defining a first inner wall to restrict movement of the first bushing; and
a stepped outer wall formed on an outer surface of the first insert, the stepped outer wall to be positioned in the drive shaft bore and to engage the valve body to position the first insert in the drive shaft bore; and
a cladding material provided in the fluid flow passageway, the cladding material to at least partially encase the first insert and the first bushing, the cladding material to encase wetted surfaces of the fluid flow passageway between the inlet and the outlet, wherein the cladding material is not applied to an inner surface of the drive shaft bore that is lined by the first insert.
7. A rotary valve comprising:
a valve body having a fluid flow passageway and a first shaft bore, the fluid flow passageway defining a first axis and the first shaft bore defining a second axis that is substantially non-parallel relative to the first axis of the fluid flow passageway;
a first insert positioned in the first shaft bore, the first insert having a first edge recessed relative to a first end of the first shaft bore and a second edge to at least partially extend in the fluid flow passageway beyond a second end of the first shaft bore opposite the first end, the first insert having a cylindrical body defining an inner surface and an outer surface and a longitudinal bore extending through an entire length of the cylindrical body defining a first opening to receive a drive shaft of the valve, the first insert including a counterbore defining a second opening to receive a bushing, the second opening coaxially aligned with the first opening, the first insert to engage an inner surface of the first shaft bore at an interface between the first shaft bore and the fluid flow passageway, the first insert to protect the inner surface of the first shaft bore from corrosion;
a first cladding material applied to wetted surfaces of the fluid flow passageway, the first cladding material to at least partially encase the second edge of the first insert; and
a second cladding material applied adjacent the first end of the first shaft bore, the second cladding material to at least partially encase the first edge of the first insert such that the first insert is positioned between the first cladding material and the second cladding material.
1. A rotary valve comprising:
a valve body having a fluid flow passageway and a first shaft bore, the fluid flow passageway defining a first axis and the first shaft bore defining a second axis that is substantially non-parallel relative to the first axis of the fluid flow passageway, the valve body defining a first shoulder located in the first shaft bore between a first end of the first shaft bore and a second end of the first shaft bore opposite the first end;
a first insert positioned in the first shaft bore, the first insert having an outer surface defining an outer step located between a first edge of the first insert and a second edge of the first insert opposite the first edge, the outer step to engage the first shoulder of the first shaft bore to locate the first insert in the first shaft bore at a desired location, the first edge being recessed relative to the first end of the first shaft bore and the second edge to at least partially extend in the fluid flow passageway beyond the second end of the first shaft bore opposite the first end, the first insert to engage an inner surface of the first shaft bore at an interface between the first shaft bore and the fluid flow passageway, the first insert to protect the inner surface of the first shaft bore from corrosion;
a first cladding material applied to wetted surfaces of the fluid flow passageway, the first cladding material to at least partially encase the second edge of the first insert; and
a second cladding material applied adjacent the first end of the first shaft bore, the second cladding material to at least partially encase the first edge of the first insert such that the first insert is positioned between the first cladding material and the second cladding material.
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This patent claims the benefit of U.S. Provisional Patent Application Ser. No. 62/238,431, filed on Oct. 7, 2015, titled “Valve Body Insert Apparatus and Related Methods,” which is incorporated herein in its entirety.
This disclosure relates generally to valves and, more particularly, to valve body insert apparatus and related methods
Valves are commonly used in process control systems to control the flow of process fluids. In severe service applications (e.g., chemical industry, refining, petrochemical industry, natural gas, paper and pulp, power industry, etc.), control valves may be subjected to highly corrosive and/or erosive service conditions that can rapidly wear or reduce the operating life of a valve. For example, wetted surfaces of the valve and/or a valve trim of the valve may be exposed to highly corrosive or erosive process fluids (e.g., containing entrained particulate, chlorides from saltwater, etc.) that can damage (e.g., remove material) and/or rapidly wear a surface of a valve made of a low corrosion resistance material such as, for example carbon steel. Such damage is exacerbated in high differential pressure applications because particulate in the fluid may impact the metallic surfaces of the valve and/or the valve trim at relatively high velocities, resulting in a significantly reduced operating life of the valve.
A rotary valve includes a valve body made of a first material and having a fluid flow passageway and a first shaft bore. The fluid flow passageway defines a first axis and the first shaft bore defines a second axis that is substantially non-parallel relative to the first axis of the fluid flow passageway. A first insert is positioned in of the first shaft bore. The insert is made of a second material different than the first material such that the second material has a higher corrosion resistance characteristic than the first material.
In another example, a rotary valve described herein includes a valve body defining a fluid flow passageway between an inlet and an outlet. The valve body has a drive shaft bore formed on a drive side portion of the valve body. A first insert is positioned in the drive shaft bore. The first insert includes a first counterbore to receive a first bushing. The first counterbore defines a first inner wall to restrict movement of the first bushing and an outer wall positioned on an outer surface of the first insert, where the outer wall is to engage the valve body to position the first insert in the drive shaft bore.
In yet another example, a method includes inserting a first sleeve in a drive shaft bore of a valve body, where the first sleeve defines a first opening to receive a drive shaft, and cladding an inner surface of the valve body defining a fluid flow passageway.
A valve body is typically made of carbon steel to reduce manufacturing costs. However, carbon steel has low corrosion or erosion resistance characteristics. In severe service applications, fabricating a valve body composed of a high corrosion or erosion resistant material such as nickel alloy material(s) significantly increases manufacturing costs. Thus, to reduce costs, cladding material composed of highly corrosion or erosion resistant material such as nickel alloy (e.g., Inconel) is applied to wetted surfaces of a valve body that are made of a low corrosion or erosion resistant material such as carbon steel. The cladding material significantly reduces damage and/or wear caused by severely corrosive or erosive process fluids that may otherwise damage surfaces of the valve composed of low corrosion resistant material, thereby increasing the operating life of the valve. Thus, the cladding material is often applied to wetted surfaces of the valve body.
Cladding material is typically coupled to the wetted surfaces of a valve body via fusion or welding. However, in some instances, cladding a shaft bore of a rotary valve body may often be challenging due to, for example, a length of the bore and/or a diameter (e.g., an inside diameter) of the bore. For example, applying cladding material to relatively long bores and/or relatively small diameter bores may be difficult, particularly via welding because a probe tip of the welding tool may not easily fit within the shaft bore. As a result, the constraints associated with the process of attaching the cladding material to the valve body often limits cladding to relatively large rotary valves (e.g., valve sizes having nominal pipe size “NPS” 18 or greater).
Additionally, rotary valves typically employ a bushing or bearing stop to properly align a valve trim (e.g., a closure member) in a flow path of a valve. The bearing stop is positioned within a shaft bore and engages a bearing to prevent movement of the bearing in a vertical and/or lateral direction relative to a flow path of the valve. In some such examples, the bushing is press-fit inside the shaft bore via an interference fit to a specific or target location. An amount of interference required to hold the bearing stop in place makes it difficult to precisely locate the bearing stop in the shaft bore at the target location, which increases the complexity of assembling the valve. For example, a bushing stop that is positioned in the shaft bore a distance between 0.010 to 0.015 inches of the target location may cause the valve trim to be improperly aligned within the valve body. An improperly aligned valve trim, for example, may not provide a tight seal when the valve is in a closed position. In some examples, a bushing stop composed of nickel alloy material may gall, making it difficult to properly position the bushing stop in the shaft bore at the target location. In some instances, an improperly located bushing in the shaft bore may not be repositioned (e.g., within 0.010 to 0.015 inches of the target location), thereby resulting in a defective or unusable valve body.
The example valve body insert apparatus and related methods disclosed herein protect surfaces of a valve body made of low corrosive or erosive resistant from corrosive or erosive conditions or environments. The example valve body insert apparatus disclosed herein may be positioned on wetted surfaces of a valve body. In particular, the example valve body insert apparatus disclosed herein line the wetted surfaces of a valve body made of low corrosion resistant material such as carbon steel with a relatively higher corrosion resistant material such as nickel alloy material(s). For example, the valve body insert apparatus disclosed herein may be used to line an inner surface of a shaft bore of a valve body. In some examples, the example valve body insert apparatus disclosed herein may be employed combination with cladding material. For example, a cladding material may be applied to wetted surfaces that are readily accessible by equipment (e.g., a probe tip) used to apply cladding and the example valve body insert apparatus disclosed herein may be applied to wetted surfaces of a valve body that are not easily accessible by equipment used to apply (e.g., weld) the cladding to a valve body. In this manner, the example valve body insert apparatus disclosed herein significantly decrease manufacturing costs associated with the time required to apply cladding to areas of a valve body that are difficult to access. The example valve body insert apparatus disclosed herein may be employed with rotary valves having a nominal pipe size (NPS) of 16 or less. In some examples, the valve body insert apparatus disclosed herein may be employed with rotary valves having a nominal pipe size (NPS) of 18 or greater. The example valve body insert apparatus disclosed herein may be composed of highly corrosion or erosion resistant material such as, for example, nickel alloy material(s). Thus, the example valve body insert disclosed herein may be made of the same material as the cladding material (e.g., Inconel material).
Additionally or alternatively, in some examples, the example insert apparatus disclosed herein facilitate assembly of a valve. For example, the example valve body insert apparatus disclosed herein properly and/or accurately locate valve trim assembly within a fluid flow passageway of the valve. In some examples, the example valve body insert apparatus disclosed herein provide an integral bearing stop. In contrast to known rotary valves that employ a bearing stop positioned within a shaft bore via press-fit, the example valve body insert apparatus disclosed herein provide a bearing stop or integral bushing that allows for a bearing to be positioned in a correct location without requiring a press-fit operation, thereby significantly reducing manufacturing complexity. The example valve body insert apparatus may include a locator (e.g., a flange or a shoulder) to allow the valve body insert to be properly and/or accurately positioned (e.g., at a target location) inside a shaft bore of a valve body during assembly. In this manner, the valve body insert apparatus properly aligns a valve trim assembly relative to a fluid flow passageway of the valve. In some examples, the valve body insert apparatus disclosed herein include a packing cup or cavity to receive a packing assembly. In some examples, the valve body insert apparatus disclosed herein provide an integral packing box ring on a drive side portion of a rotary valve body, thereby eliminating the need to procure a packing box ring (e.g., a packing box ring made of nickel alloy). Thus, the example valve body insert apparatus disclosed herein facilitates manufacturing and/or protects low corrosion resistance material from harsh conditions.
To protect inner surfaces of the first shaft bore 204 and the second shaft bore 206 of the valve body 102 from wear and/or damage in severe fluid condition applications, the example rotary valve 100 of the illustrated example includes a first insert or sleeve 212 positioned in the first shaft bore 204 and a second insert or sleeve 214 positioned in the second shaft bore 206. In particular, the first insert 212 and the second insert 214 of the illustrated example protect the inner surfaces of the respective first and second shaft bores 204 and 206 without having to overlay cladding material (e.g., nickel alloy material) along the inner surfaces of the first shaft bore 204 and/or the second shaft bore 206 that are engaged or covered by (e.g., the outer surfaces 330 and 418 of) the first and the second inserts 212 and 214, respectively. In other words, the first and second inserts 212 and 214 of the illustrated example are provided in place of cladding material. The first and second inserts 212 and 214 significantly reduce manufacturing complexity because the first and second inserts 212 and 214 eliminate the need to overlay cladding material on the inner surfaces of the first shaft bore 204 and/or the second shaft bore 206. For example, applying or overlaying cladding material to shaft bores having a diameter less than 3 inches may be difficult to achieve because a probe tip of a welding apparatus may not fit inside a the first shaft bore 204 to apply or weld the cladding material to the inner surface of the first shaft bore 204. In some examples, the rotary valve 100 may employ only the first insert 212 and the second shaft bore 206 may be provided with the cladding material instead of the second insert 214. To protect the inner surfaces of the first and second shaft bores 204 and 206 from wear and/or damage, the first and second inserts 212 and 214 of the illustrated example are made of a highly corrosion resistant material such as, for example, nickel alloy, stainless steel and/or other material(s) having a relatively high corrosion resistance characteristic(s). The first and second inserts 212 and 214 may be formed via machining and/or any other manufacturing process(es).
In addition or as an alternative to protecting the first and second shaft bores 204 and 206 from corrosive conditions, the example first and second inserts 212 and 214 position or locate (e.g., align) the valve trim 110 relative to the fluid flow passageway 104 of the valve body 102. As a result, the first and second inserts 212 and 214 eliminate a need for a bearing stop typically used in some rotary valves, thereby significantly reducing manufacturing complexity (e.g., eliminating the press-fit operation noted above). When the first and second inserts 212 and 214 are used in non-corrosive or non-harsh environments and are provided to facilitate manufacturing and/or assembly of the rotary valve 100, the first and second inserts 212 and/or 214 may be composed of, for example, carbon steel or other low corrosion resistance material(s).
The valve trim 110 of the illustrated example includes a drive shaft 216 that is received by the first insert 212 and the second insert 214. The drive shaft 216 is coupled to a closure member 218 (e.g., via fasteners, pins, etc.) that is disposed within the fluid flow passageway 104 to control fluid flow between the inlet 106 and the outlet 108. In the illustrated example, the closure member 218 is a disk having a peripheral edge 220 that sealingly engages a valve seat or annular sealing surface 222 (e.g., a seal ring) disposed in the central opening 202 to prevent or restrict fluid flow through the rotary valve 100 when the rotary valve 100 is in the closed position. The drive shaft 216, via an actuator (e.g., an electric actuator), drives or rotates the closure member 218 between the closed position and the open position to control the flow of fluid through the rotary valve 100. In other example implementations, the closure member 218 can be any suitable closure member such as, for example, a ball valve, a segmented ball, etc. The rotary valve 100 may include a packing 224 that engages or surrounds the drive shaft 216 to prevent or restrict process fluid in the fluid flow passageway 104 from flowing up along the drive shaft 216 and to the environment via the first shaft bore 204. Bearings 226 and 228 aid the drive shaft 216 and the closure member 218 in alignment and rotation, and reduce friction when the drive shaft 216 rotates the closure member 218 between the open and closed positions. In particular, the first insert 212 positions the bearing 226 in the first shaft bore 204 and the second insert 214 positions the bearing 228 in the second shaft bore 206. For example, the first and second inserts 212 and 214 and the bearing 226 and 228 align (i.e., center) the closure member 218 in the fluid flow passageway 104 relative to the longitudinal axis 208 of the first and second shaft bores 204 and 206 and/or relative to the longitudinal axis 210 of the fluid flow passageway 104.
For example, in operation, a pressure of a process fluid flowing through the fluid flow passageway 104 of the valve body 102 from the inlet 106 is sensed in the second shaft bore 214 and applies a thrust load to the closure member 218 via the shaft 216 (e.g., an upward force in the orientation of
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Although certain apparatus, methods and articles of manufacture have been described herein, the scope of coverage of this patent is not limited thereto. To the contrary, this patent covers all apparatus, methods and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents.
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